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					DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
                                        Montecarlo,
                                        Montecarlo, June 7-9 2000




First Southern European Technology Conference
First Southern European Technology Conference


                CAE Design approach
                 CAE Design approach
           to develop applicative solutions
            to develop applicative solutions
       in automotive polymer based systems
        in automotive polymer based systems


  M. Chiara Ferrari, Filippo Gallieri
  M. Chiara Ferrari, Filippo Gallieri
  Montecarlo, June 7-9 2000
  Montecarlo, June 7-9 2000
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
                              Montecarlo,
                              Montecarlo, June 7-9 2000




        DESIGN & CAE
        DESIGN & CAE
        Business Support Tool
        Business Support Tool
  to develop applicative solutions in
   to develop applicative solutions in
  automotive polymer based systems
  automotive polymer based systems
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
                                            Montecarlo,
                                            Montecarlo, June 7-9 2000



 Design & CAE: a powerful tool in the Business Support
 Design & CAE: a powerful tool in the Business Support


 Computer Aided Engineering
 Computer Aided Engineering


         Design
         Design


   Testing & validation
   Testing & validation
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
                                           Montecarlo,
                                           Montecarlo, June 7-9 2000

CAE TOOLS
                                      Product

                               actual service conditions

                           main variables/part performances
       Simulation

   computer calculation
        replacing

   qualitative/empirical
         approach
                                       Process

                                 tools and conditions

                               process influence on part
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
                                   Montecarlo,
                                   Montecarlo, June 7-9 2000




New material/processes
New material/processes         Design solutions
                               Design solutions



                CAE ADVANTAGES




Production Process
Production Process       Tests (homologation ...)
                         Tests (homologation ...)
 DESIGN & CAE ACTIVITY
 DESIGN & CAE ACTIVITY
                                                    Montecarlo,
                                                    Montecarlo, June 7-9 2000

 CAE ADVANTAGES
 CAE ADVANTAGES

• New material/processes:
    - no process tool building during the preliminary evaluation phase
    - critical issues investigated by simulation


• Design solutions:
    - no prototype building up
    - several solutions evaluated and compared in short time:
                - materials
                - mechanical constraints
                - geometry
 DESIGN & CAE ACTIVITY
 DESIGN & CAE ACTIVITY
                                                     Montecarlo,
                                                     Montecarlo, June 7-9 2000

 CAE ADVANTAGES

• Tests (homologation ...):
        - the number is dramatically reduced;
        - main tests are focused on the final solution;
        - possible flops are predicted and solved on the computer

• Production Process:
      - avoiding tools judged inadequate once already set up
      - part quality:
            - part performances foreseen in the design phase are
              respected
            - controlled defects due to process
      - time/costs are optimised
 DESIGN & CAE ACTIVITY
 DESIGN & CAE ACTIVITY
 CAE & MONTELL
 CAE & MONTELL                                       Montecarlo, June 7-9 2000
                                                     Montecarlo,



• Supporting to Montell product development
      - property profile for specific applications
      - directions for improvement


            • Driving the customer to Montell materials
                   - advanced properties
                   - best material/design system


                          • Establishing Montell as a leading supplier
                            to the technical industry:
                                   - differentiated offering
                                     (product and service)
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
                                       Montecarlo,
                                       Montecarlo, June 7-9 2000




                        • Internal:
                          new material/application
                          development
             R&D
             R&D

       CAE:
A KEY FACTOR FOR


            Business
            Business
                        • External:
                          penetration into the market
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
                                 Montecarlo,
                                 Montecarlo, June 7-9 2000




    Car dashboards:
    from new concepts to
    first applicative projects
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
New concepts on dashboards
                                               Montecarlo,
                                               Montecarlo, June 7-9 2000




                         OBJECTIVE:
                         OBJECTIVE:
                         cost reduction
                         cost reduction

                                         Computer simulation
                                          Computer simulation
Dashboard system complexity
 Dashboard system complexity                   in the early
                                                in the early
causes aabig influence of design
 causes big influence of design             feasibility stage
                                             feasibility stage
(shape, assembly solutions) on
 (shape, assembly solutions) on          to compare solutions
                                          to compare solutions
final performances.
 final performances.                 (materials, design, thickness)
                                      (materials, design, thickness)
 DESIGN & CAE ACTIVITY
 DESIGN & CAE ACTIVITY
 New concepts on dashboards: creep as a key issue
                                                           Montecarlo,
                                                           Montecarlo, June 7-9 2000


  Cycle: heating to 85°C, 22 hours creep, cooling to 23°C
  Cycle: heating to 85°C, 22 hours creep, cooling to 23°C
  Example of Z displacement distribution after 22 hours creep
  Example of Z displacement distribution after 22 hours creep
         at 85°C and cooling to room temperature
          at 85°C and cooling to room temperature




example: Renault X76
customer: Allibert
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
New concepts on dashboards: creep as a key issue
                                                          Montecarlo,
                                                          Montecarlo, June 7-9 2000



Cycle: heating to 85°C, 22 hours creep, cooling to 23°C
Cycle: heating to 85°C, 22 hours creep, cooling to 23°C

Displacement comparison of selected points
Displacement comparison of selected points


 Material
  Material                        BR131G BR131G CR250F CR1152F
                                   BR131G BR131G CR250F CR1152F
 Density
  Density                           1.14
                                     1.14  1.14
                                            1.14  1.04
                                                   1.04  0.97
                                                          0.97
 Thickness of the dashboard
  Thickness of the dashboard         2.8
                                      2.8   2.4
                                             2.4   2.8
                                                    2.8   2.8
                                                           2.8

 Upper right corner
  Upper right corner                0.85
                                     0.85   0.79
                                             0.79    1.25
                                                      1.25         2.25
                                                                    2.25
 of central console
  of central console

 Top of instrument cover
  Top of instrument cover           1.21
                                     1.21   1.08
                                             1.08    1.27
                                                      1.27         1.73
                                                                    1.73
 (“visière”)
  (“visière”)

 Bottom of glove box
  Bottom of glove box               2.35
                                     2.35   2.43
                                             2.43    2.43
                                                      2.43         2.45
                                                                    2.45

 Local relative displacement
  Local relative displacement       0.70
                                     0.70   0.90
                                             0.90    0.36
                                                      0.36         0.56
                                                                    0.56
 in right horizontal area
  in right horizontal area
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
                            Montecarlo,
                            Montecarlo, June 7-9 2000




  STRATEGY:
   STRATEGY:
  concurrent engineering and
   concurrent engineering and
  simulation based design offered
   simulation based design offered
  to selected partners
   to selected partners
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
                                                  Montecarlo,
                                                  Montecarlo, June 7-9 2000




•• Montell Design Support:
   Montell Design Support:
     --Static behaviour
       Static behaviour
     --Long term thermal stability (thermal/creep simulations)
       Long term thermal stability (thermal/creep simulations)
     --Head impact simulation (ECE R 21 Standard)
       Head impact simulation (ECE R 21 Standard)
     --Dynamic behaviour (Vibration)
       Dynamic behaviour (Vibration)
     --Moldfilling simulation for all dashboard components
       Moldfilling simulation for all dashboard components



•Applicative project for dashboard development grades
 •Applicative project for dashboard development grades
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
                                                 Montecarlo,
                                                 Montecarlo, June 7-9 2000



Part performances (static, thermal/creep, head impact, vibration)
Part performances (static, thermal/creep, head impact, vibration)
main phases ::
main phases

••Preliminary feasibility calculation with simplified assumptions:
  Preliminary feasibility calculation with simplified assumptions:
  highlight of general behaviour, does it work?
   highlight of general behaviour, does it work?

••Detailed calculation:
  Detailed calculation:
     -- problem solving and optimisation on single components
         problem solving and optimisation on single components
     -- evaluation of different material solutions
         evaluation of different material solutions

••Rework of design according to CAE guidelines (customer)
  Rework of design according to CAE guidelines (customer)

••Possible last calculation on final design
  Possible last calculation on final design
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
Dashboard: Head impact ECE R 21   Montecarlo,
                                  Montecarlo, June 7-9 2000




         IMPACT
          IMPACT
         POSITIONS
          POSITIONS
         DESIGN & CAE ACTIVITY
         DESIGN & CAE ACTIVITY
         Dashboard: Head impact ECE R 21
          Dashboard: Head impact ECE R 21   Montecarlo,
                                            Montecarlo, June 7-9 2000




Fig 18
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
Dashboard: Thermal cycle AF
 Dashboard: Thermal cycle AF           Montecarlo,
                                       Montecarlo, June 7-9 2000




                                     66H
                                       H
                                             85°C
                                              85°C




                     16 H
                      16 H
         40°C
          40°C




                               33H
                                 H
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
Dashboard: Thermal cycle AF
Dashboard: Thermal cycle AF   Montecarlo,
                              Montecarlo, June 7-9 2000
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
Dashboard: Thermal cycle AF
Dashboard: Thermal cycle AF   Montecarlo,
                              Montecarlo, June 7-9 2000
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
                          Montecarlo,
                          Montecarlo, June 7-9 2000




  Dashboard Component:
  Dashboard Component:
  Manufacturing process design
  Manufacturing process design
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
Dashboard : Manufacturing process design
                                                   Montecarlo,
                                                   Montecarlo, June 7-9 2000

Process simulation: main phases

• Preliminary calculation:
     - choice of best manufacturing process
       (injection molding?, traditional? sequential?)
     - evaluation of different materials
     - evaluation of different gating solutions

• Final calculation:
     - runner system balancing
     - investigation on process parameters influence (packing)

• Special calculations for critical parts (injection molding):
     - cooling
     - warpage
  DESIGN & CAE ACTIVITY
  DESIGN & CAE ACTIVITY
  Dashboard: Manufacturing process design
                                                Montecarlo,
                                                Montecarlo, June 7-9 2000

Coiffe & runner system finite element model 1
  DESIGN & CAE ACTIVITY
  DESIGN & CAE ACTIVITY
  Dashboard: Manufacturing process design
                                                                                               Montecarlo,
                                                                                               Montecarlo, June 7-9 2000

Runner system dimensions [mm]


                                      Cold sprues                 Cold runners
                                 G1 , G3 , G4 , G5 , G6       G1 , G3 , G4 , G5 , G6
                                      Ø= 6 to 10                     Ø= 10
                        G5


                                                                       G4
    Ø= 24-8

                                                        Ø= 20-8
                                                                                                                           G6
                                           G1
               Ø= 20
                                                                                              G3
                                                                                                            Ø= 24-8
                                                                  G2
                    Ø= 20
                                Ø= 20-8
                                       i) Ø= 16                    Ø= 20
                                                          i) Ø= 14-6
                                       ii) Ø= 20                                Ø= 20-8
                                                          ii) Ø= 22-8
 G1 , G2 , G3 , G5 , G6 Gates               G4 Gate                               G2 , Cold sprue           G2 , Cold runner
       (width x length x tk)          (width x length x tk)                         Ø= 5 to 8                     Ø= 8
 thin area 20 x 2 x 1.8          thin area 120 x 2 x 1.8
 thick area 20-0 x 8 x 8         thick area 120 x 8 x 8                This is the only difference between type i) and type ii)
  DESIGN & CAE ACTIVITY
  DESIGN & CAE ACTIVITY
  Ddashboard: Manufacturing process design
                                                                        Montecarlo,
                                                                        Montecarlo, June 7-9 2000

Molding machine parameters & Variable limits for PP
Molding machine parameters & Variable limits for PP


                                               Mold temperature
                                                    40 deg.C                      Clamp force
                                                                                  1300 Tonne


                                       Max. Pressure
                                       No Restraints
 Variable limits for PP:

 Max. Pressure         = 90¸100 MPa
 Max shear stress      = 0.25 MPa
 Max. shear rate       = 100000 1/s



                                                                         Melt temperature
                                                                             250 deg.C
                                                            Fill time
                                                            6-8 sec
  DESIGN & CAE ACTIVITY
  DESIGN & CAE ACTIVITY
  Ddashboard: Manufacturing process design
                                             Montecarlo,
                                             Montecarlo, June 7-9 2000

Fill time [s] & Weld lines
 Fill time [s] & Weld lines
  DESIGN & CAE ACTIVITY
  DESIGN & CAE ACTIVITY
  Dashboard: Manufacturing process design
                                            Montecarlo,
                                            Montecarlo, June 7-9 2000

Pressure at end of filling [MPa]
 Pressure at end of filling [MPa]
  DESIGN & CAE ACTIVITY
  DESIGN & CAE ACTIVITY
  Dashboard: Manufacturing process design
                                                      Montecarlo,
                                                      Montecarlo, June 7-9 2000

Clamp force trend [Tonne]




                              Max value = 740 Tonne
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
Dashboard: Manufacturing process design
                                          Montecarlo,
                                          Montecarlo, June 7-9 2000
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
HSBM Thin wall bumper concept
                                                             Montecarlo,
                                                             Montecarlo, June 7-9 2000




             CAE support to concept development
             CAE support to concept development


             Evaluation of thickness reduction feasibility
             Evaluation of thickness reduction feasibility
                       and design optimization
                        and design optimization


      Structural performances
       Structural performances                 Molding technology
                                               Molding technology
       e.g. thermal/creep behaviour
        e.g. thermal/creep behaviour             e.g. sequential injection
                                                  e.g. sequential injection


                               CAE simulations as aakey issue
                               CAE simulations as key issue
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
Thermal/creep cycle simulation on bumpers
Thermal/creep cycle simulation on bumpers                   Montecarlo,
                                                            Montecarlo, June 7-9 2000



                                      ••Temporary dilatation due to CLTE
                                         Temporary dilatation due to CLTE
 High temperature effect              ••Possible permanent deformations
                                         Possible permanent deformations
                                        due to dilatation and weight
                                         due to dilatation and weight


  To allow evaluation of material behaviour and design changes effect:
  To allow evaluation of material behaviour and design changes effect:

            ••Simulation of the whole cycle (heating, creep, cooling)
               Simulation of the whole cycle (heating, creep, cooling)
            ••Material nonlinearities considered (CLTE vs. temperature,
               Material nonlinearities considered (CLTE vs. temperature,
               stress/strain vs. temperature, creep vs. time, temp., stress)
                stress/strain vs. temperature, creep vs. time, temp., stress)
            ••Temperature distribution: constant (e.g.oven) or variable
               Temperature distribution: constant (e.g.oven) or variable
               along the surface and across thickness (e.g. sunload effect)
                along the surface and across thickness (e.g. sunload effect)
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
Thermal/creep cycle simulation on bumpers
Thermal/creep cycle simulation on bumpers            Montecarlo,
                                                     Montecarlo, June 7-9 2000




                         Local temporary deformation
                          Local temporary deformation
                         during high temperature cycle
                          during high temperature cycle
DESIGN & CAE ACTIVITY
DESIGN & CAE ACTIVITY
Thermal/creep cycle simulation on bumpers
Thermal/creep cycle simulation on bumpers             Montecarlo,
                                                      Montecarlo, June 7-9 2000




                        Local final deformation after
                         Local final deformation after
                        high temperature cycle and cooling
                         high temperature cycle and cooling
     DESIGN & CAE ACTIVITY
     DESIGN & CAE ACTIVITY
     CAE: A KEY FACTOR FOR MONTELL
                                                                       Montecarlo,
                                                                       Montecarlo, June 7-9 2000




          CUSTOMER WORLD

IN    Design Idea         Preliminary Design                  MONTELL    Static
                                                         DESIGN & CAE WORLD Impact
                                                                                             Thermal

         !                    Prototype        DEVELOPMENT
                                                                             MATERIAL
                                                                              CHOICE
                                                                                                   Creep

        Flops                                                                                      Fatigue

                                                                                              Vibration


                                               PROBLEM SOLVING          IMPROVEMENTS
                PRODUCTION
                                                                                     Injection molding
                                                                                      Injection molding
                    OUT




                                          New material
                                                                                       Gas-assisted
                                                                                        Gas-assisted
                                                                                       inj. Molding
                                                                                        inj. Molding
                                                            FINAL DESIGN         Thermoforming
                                                                                  Thermoforming
                                                                Extrusion Blow molding
                                                                 Extrusion Blow molding

				
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